Container Production Plant Retooling Apparatus
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Solution Overview
Problem
Existing plants for producing containers face challenges in retooling operations, particularly in blocked designs, where personnel deployment is high and efficient, automated retooling methods are not disclosed.
Innovation Solution
A plant and method for producing containers that includes a retooling apparatus with tools and robots for automated or semi-automated retooling of production and blow molding machines, utilizing a buffer device to manage preform transport during retooling, and a control unit to optimize machine operation, minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If retooling is performed manually in blocked plants, then personnel can perform necessary component exchanges for format changes, but personnel deployment is high and retooling efficiency is low
Solution Approach 1:
The plant is divided into separate production lines (injection molding line and blow molding line) that can be retooled independently. The retooling apparatus is segmented into modular components that can service different machine types, allowing systematic automation without overwhelming complexity
Solution Approach 2:
A buffer device is introduced as an intermediary between the injection molding machine and blow molding machine. This buffer decouples the two production lines, allowing one line to be retooled while the other continues operating, thereby enabling automated retooling without complete production shutdown
2Productivity
If blocked plant design is used with synchronized throughput, then immediate transport and processing of preforms occurs, but retooling requires complete production shutdown
Solution Approach 1:
The buffer device is pre-filled with preforms before retooling begins. This preliminary action ensures that the blow molding line can continue operating with stored preforms while the injection molding line is retooled, preventing complete production shutdown
Solution Approach 2:
The buffer device maintains continuous supply of preforms to the blow molding line during retooling operations. By decoupling the synchronized throughput requirement, the blow molding line continues its useful action without interruption while the injection molding line undergoes retooling
3Adaptability or versatility
If format change retooling is performed, then different container types can be produced, but production downtime occurs during component exchange
Solution Approach 1:
Different container types are produced by exchanging only the necessary mold components rather than entire machines. The segmented approach allows selective replacement of injection molding tools or blow molds while leaving the rest of the production line intact, reducing retooling downtime
Solution Approach 2:
Required mold components for format changes are prepared and staged before retooling begins. This preliminary preparation allows rapid component exchange once the retooling process starts, minimizing production downtime while maintaining flexibility for different container types
Data Source
AI summary
The disclosure relates to a plant for producing containers, the plant comprising a production machine for producing preforms, a blow molding machine for producing containers from the preforms and a transport device for transporting the preforms from the production machine to the blow molding machine, wherein the plant comprises a retooling apparatus for retooling at least one component of the production machine and/or the blow molding machine.